Method of forming and casing books and product thereof

ABSTRACT

An uncased book is first prepared. The outside end papers on each of the top and bottom of the book consists of a sheet of paper, flexible plastic, cloth, or the like, coated with pressure-sensitive adhesive with the sensitive surface outermost and protected by a protective release covering scored in at least two lines adjacent to the inner edge. Spaced holes are punched, drilled or otherwise formed adjacent to the inside margin of each sheet of the book, including the end papers. A first narrow strip of plastic having projecting studs spaced the same as the holes and a second narrow strip formed with corresponding holes are provided. The studs are inserted through the holes in the endpapers, sheets and second strip and the strips forced toward each other, compressing the sheets there-between. The excess stud lengths are cut off and heads similar to rivet heads formed, securing the uncased book in assembled condition. A case is provided similar to conventional book cases. Initially such case has a central spine strip of double-face, pressure-sensitive material, one face adhered to the cover, the other covered by a detachable protective release strip. To assemble the book to the case, the first step is to remove the protective release strip from the spine strip, then to press the spine of the uncased book so that it adheres to the middle of the spine strip and to bend the excess width of the spine strip around the outside of the plastic strips. Next a narrow band of protective release cover is removed to expose about three-eighths inch of each end leaf immediately outside the plastic strips. The case is then creased to form spine beads and creases between the beads and the boards of the case. Finally, the remainder of the protective release covers are removed, causing the end leaves to be secured to the insides of the covers of the case.

ilnited States Patent [191 Abildgaard et al.

[451 May 1,1973

[ METHOD OF FORMING AND CASING BOOKS AND PRODUCT THEREOF [75] Inventors:William H. Abildgaard, Los Altos Hills; Charles T. Groswith, III, PaloAlto, both of Calif.

[73] Assignee: Abildgaard Laboratories, Inc.,

Mountain View, Calif.

22 Filed: Oct. 8, 1970 21 Appl.No.: 79,086

Related U.S. Application Data [63] Continuation-impart of Ser. No.799,045, March 13, 1969, Pat. No. 3,596,929, and a continuation-in-partof Ser. No. 872,134, Oct. 29, 1969.

FOREIGN PATENTS OR APPLlCATlONS 8/1960 Germany ..28l/29 2/1939 Germany..281/21 Primary Examiner-Lawrence Charles Att0rney-Julian Caplan 57ABSTRACT An uncased book is first prepared. The outside end papers oneach of the top and bottom of the book consists of a sheet of paper,flexible plastic, cloth, or the like, coated with pressure-sensitiveadhesive with the sensitive surface outermost and protected by aprotective release covering scored in at least two lines adjacent to theinner edge. Spaced holes are punched, drilled or otherwise formedadjacent to the inside margin of each sheet of the book, including theend papers. A first narrow strip of plastic having projecting studsspaced the same as the holes and a second narrow strip formed withcorresponding holes are provided. The studs are inserted through theholes in the end-papers, sheets and second strip and the strips forcedtoward each other, compressing the sheets there-between. The excess studlengths are cut off and heads similar to rivet heads formed, securingthe uncased book in assembled condition. A case is provided similarto'conventional book cases. lnitially such case has a central spinestrip of double-face, pressure-sensitive material, one face adhered tothe cover, the other covered by a detachable protective release strip.To assemble the book to the case, the first step is to remove theprotective release strip from the spine strip, then to press the spineof the uncased book so that it adheres to the middle of the spine stripand to bend the excess width of the spine strip around the outside ofthe plastic strips. Next a narrow band of protective release cover isremoved to ex ose about hree-eighths inch of each end leaf imme latelyoutside the plastic strips. The case is then creased to form spine beadsand creases between the beads and the boards of the case. Finally, theremainder of the protective release covers are removed, causing the endleaves to be secured to the insides of the covers of the case.

7 Claims, 18 Drawing Figures PATENTEDMY 1 W I 3,730,560

SHEET 1 [IF 5 INVENTOR.

WILL/AM H Aa/LosAA/a BY CHA RL ES 77 GROSW/ THE ATTORNEY PATENTEDW 119733,730,560

SHEET 3 OF 5 INVENTOR. W/LL/AMHAB/LDGAARD CHARLES I'GROSW/THHZ ATTORNEYMETHOD OF FORMING AND CASING BOOKS AND PRODUCT THEREOF This invention isa continuation-in-part of our copending applications, Ser. No. 799,045,filed Feb. 13, 1969, now U.S. Pat. No. 3,596,929 and Ser. No. 872,134,filed Oct. 29, 1969. v

This invention relates to a new and improved, method of forming andcasing books and the product thereof.

A principal object and advantage of the present invention is to greatlyreduce the number of operations required to bind an uncased book and tocase said book. The labor required is very materially reduced; the useof existing bindery equipment is almost entirely eliminated; and theamount of additional equipment required is minimal and inexpensive. Moreparticularly, conventional book binding requires a large number ofsewing, glueing, beading and rounding steps, each of which normallyrequires specialized equipment and, further, the casing in of theuncased book required glueing and fabricating steps. All of theforegoing steps are either eliminated or greatly simplified by practiceof the present invention.

Conventional bindery practice requires utilization of large areas ofbindery floor space, since the various parts which are ultimatelyassembled in the cased book are ordinarily spread out and must be leftin spread condition while glue dries and while other portions are beingcompleted and assembled. Hence, not only is the amount of labor andmachinery greatly reduced by practice of the present invention, but eventhe floor space required in a bindery is reduced because of the factthat it is not necessary to spread out the book parts as has heretoforebeen the practice.

Ordinary practice at the present time requires the collection of thesheets of the book in signatures which are generally four sheets ormultiples thereof folded to page size and sewn and glued to a backingstrip. Such bindery practice limits the versatility of fabrication andmakes it well nigh impossible to insert or delete sheets once themake-up of the book has been commenced. In accordance with the presentinvention, since the sewing and glueing of signatures is eliminated, theindividual sheets forming the book may be made up and collated orotherwise assembled as required and as changed from time to time assheets may be added or deleted or altered.

Accordingly, the present invention makes printing more flexible sincethe formation of .the book is not restricted to the four-page technique.

A further feature of the invention is the reduction in the amount ofskilled labor required. The operator of the equipment used to practicethe present invention does not require extensive training in order topractice the method ofthe invention.

The present invention is compatible with standard book manufacture, butthere are certain differences in the construction which, although notreadily apparent to the eye (without dissecting the book), make for astronger and more durable book construction.

One of the features of the invention which improves the durability ofthe book is the fact that the end leaves and their reinforcement stripsare locked under plastic strips which also lock the sheets of the booktogether. In conventional binding practice, the end leaves are generallynot secured to the top and bottom signatures in a durable manner. Hence,many bindings fail where the end leaves are joined to the front and backcovers of the case. The present invention has considerable advantageover prior construction in that these areas are more securelyreinforced.

One of the important steps in conventional book manufacture is theformation of a bead between the hinge area of each cover and the spinecover. Such bead is desirable in order to facilitate opening of the bookwithout breaking the binding. The present invention automaticallyprovides a bead along each edge of the spine, said bead being shaped bythe plastic strips which extend along the top and bottom adjacent to thespine edge of the uncased book formed in accordance with the presentinvention. The casing material fits around the strips and thus forms thebead.

Another feature of the invention is the fact that the binding isextremely flexible. When the book is open a very deep gutter isachieved. Hence, the page is opened fiat and is legible as close to thespine as in conventional book construction.

-An additional feature of the foregoing advantage of the presentinvention is the fact that since the book opens in a deeper gutter, anyselected page will fit on the platen of a copying machine, lying flat onthe platen without danger of breaking the binding.

In accordance with the present invention, holes are formed adjacent tothe inner margin of each sheet, the holes being spaced apart atintervals of approximately 1 inch. Such holes maybe formed by punchingthe sheets in groups or drilling all of the sheets of the assembledbook. However, the holes may also be formed in an offset printing presswhen the sheets are printed thereby eliminating the separate punchingsteps of conventional practice.

Other objects of the present invention will become apparent upon readingthe following specification and referring to the accompanying drawingsin which similar characters of reference represent corresponding partsin each of the several views.

In the drawings:

FIG. 1 is a perspective view of a male binding strip used in thepractice of the present invention.

FIG. 2 is a perspective view of a female strip.

FIG. 3 is an exploded perspective view of the sheets of the bookimmediately prior to binding.

FIGS. 4 to 8 inclusive are schematic views illustrating steps in formingthe uncased book.

FIG. 9 is a perspective view of an uncased book formed in accordancewith the invention.

FIG. 10 is a fragmentary perspective view of the case for the book.

FIG. 11 is a fragmentary perspective view showing the beginning ofattaching the uncased book to its case.

FIGS. 12 to 14 are fragmentary sectional views showing further steps inthe attachment of the uncased book to the case.

FIG. 15 is a fragmentary sectional view through the cased book.

FIG. 16 is a fragmentary end elevation of a modification.

FIGS. 17 and 18 are fragmentary perspective view of steps in thefabrication of a further modified book.

FABRICATION OF THE UNCASED BOOK Nos. 872,134 and 799,045, in certainrespectsi'ln practice of the method, two plastic strips 26 and 29 areemployed, formed of polyvinyl chloride or other suitable material. Thestrips are approximately one-fourth inch in width and one-sixteenth inchin thickness and are of a length equal to the length of the sheets ofthe book. At approximately 1 inch intervals, spaced along the length ofstrip 26 and indented somewhat from the ends, are studs 27 approximatelythree thirty-seconds inchin diameter and formed with tapered points 28at their tops. Second strips 29 are also provided formed with holes 31at intervals corresponding to studs 27 and of a size to accept saidstuds. Holes 31 are formed with countersinks 32 on one surface. Ashereinafter explained, excess lengths of studs 27 are cut off and theprotruding ends of the studs are deformed to fill the countersinks 32and to form heads 33 similar to rivets.

Each sheet 21 which is to form the book is punched or drilled with holes22 spaced inward from the inside margin of sheet 21a distance ofapproximately oneeighth inch. The holes 22 may be formed in the printingof the sheets 21 within the capacity of the press on which the sheetsare printed. In accordance with common book practice, one or more endleaves 23, similarly punched with holes 22 are placed on the top andbottom of the pile of sheets 21 making up the printed matter of thebook. Each outer end leaf 23 has a pressure-sensitive adhesive on itsouter face and is initially protected by a detachable cover 24. Cover 24is formed with a first longitudinal slit 25a spaced from the inner edgethe width of strip 26 or 29, a second slit 25b spaced inward of 25aabout three-eighthsinch, and, optionally, a third slit 250 about midwaybetween slit 25b and the outside edge of leaf 23. Holes 22 pass throughleaf 23 and through cover 24 between slit 25a and the inner edge of 24.

In assembly of the uncased book, strip 29, with countersink 32 downmost,is positioned on a support 37, the said support 37 being grooved toreceive the strip 29 and also being apertured immediately below theholes 31. The front end leaf 2 3 is positioned along with its cover 24above strip 29 with the holes 22 aligned-with holes 31. The sheets 21are also placed on top of front end leaves 23 and the back end leaves 23are placed on the top of the pile. This assembly is illustrated in FIG.4. Thereupon strip 26 is applied from the top of the pile by insertingthe points 28 through the holes 22 in the end leaves 23 and sheets 21and also through the holes 31. The points 28 extend below the strip 29 adistance depending upon the thickness of the sheets 21, .hence subjectto considerable variation. (FIG. 5) Thereupon a pressure bar 36 ispressed against strip 26 compressing the sheets 21 between the twostrips 26 and 29 (FlG. 6). Heated knife blades 38 are moved from rightto left as viewed in FIG. 7 to cut off studs 27 at a distance slightlybelow the bottom of strip 29.-The apertures in support 37 permit theinward movement .of the blades 38. (FIG. 7). Thereupon the blades 38 areraised, melting and deforming the material on the ends of studs 27 sothat the countersink 32 is filled by the material forced therein by theupward movement of blades 38 (FIG. 8). The blades 38 are retracted andthe pressure of bar 36 is maintained until the plastic has set. Theheads 33 thus formed in the countersinks 32 secure the strips 26 and 29in spaced position with the sheets 21 and end leaves 23 securedthere-between. Thereby uncased book 41 is completed.

ASSEMBLY OF CASE The case 46 to which the uncased book 41 is assembledis subject to considerable variation. Essentially, standard cases 46 maybe used but considerable variation may also be made therein. The case 46shown in FIG. 10 has a covering 47 of cloth, plastic, natural orartificial leather, or other suitable book-binding material. Thematerial 47 is cut in a size sufficient to accommodate the page size andspine width of the uncased book 41 with overlaps to form the tum-ins 52,53. Extending longitudinally of the material 47 at the center is a strip48 of a resilient material such as plastic foam which is attached to theinside of covering 47 and its upper surface is pressure-sensitive andcovered with a protective strip 48a. Strip 48 is of a length equal tothe height of the completed book and of a width at least equal to thethickness of the uncased book 41 and may be wider by twice the width ofstrip 26 or 29. At either side of strip 48 extending longitudinally ofthe material 47 is a hinge-forming area 49 of a width to form thecompleted bead and binge crease hereinafter described. These areas 49are the most flexible portion of the completed cover. Outwardly of theareas 49 are the cover boards 51 which conventionally are made ofcardboard and are of a dimension such as to project beyond the top,bottom and outside edges of the sheets 21 making up the uncased book 41so as to protect the uncased book from damage, all as in accordance withconventional book binding practice. Prior to application of strip 48,boards 51 are glued to the inside of covering 47, then the top andbottom of the material 47 is turned in to form. the top and bottomturn-ins 52 which adhere to the boards 51. Similarly the side edges areturned in to form the edge turn-ins 53. Comers54 are mitered inaccordance with conventional bookbinding practice. Thereupon, strip 48and covering 48a are applied.

The assembly of the uncased book 41 to the case 46 is illustrated inFIGS. 10-15. With the boards 51 uppermost, covering 48a is stripped offand the spine edge of the uncased book 41 is positioned centered withrespect to the strip 48 and caused to adhere thereto. The excess widthof strip 48 is folded around and secured to the outsides of strips 26and 29. The narrow strips of cover 24 between slits 25a and 25b are thenpeeled off. A blunt tool is drawn along the outside of covering material47 at hinge forming area 49 immediatelyoutside the outer edges of strips26 and 29 causing material 47 to adhere to cover 24 in longitudinalhinge creases 58 at the hinge forming areas 49.

Thereupon, the cover 24 outside slits 25b is removed in a singleoperation or, where third slit 250 is used in two operations, and eachend leaf 23 is caused to adhere to the inside of board 51. Directingattention to FIG. 13, the area 49 overlies the strip 26, 29 and extendsthere-beyond and is formed with a crease 58 in the area between thestrip 26 and board 51. This provides a bead 59 inward of the crease 58which is given fullness by the thickness of the strips 26, 29. Hence,the

book has a front and back covers 56 and a spine covering 57 andresembles high grade bound books in the presence therein of the creases58 and beads 59.

Directing attention to FIG. 16, a modification of the preceding book isshown. Many of the elements of this modification are very similar to thepreceding, and the same reference numerals, followed by the subscript aare used to designate similar elements. In this modification case 460 isfastened under strips 26a and 29a. Thus holes 66, corresponding inspacing to studs 27a are formed in each of the hinge forming areas 490.The case is laid around the sheets 21a and end leaves 23a with holes 66aligned with the holes (not shown, but similar to holes 22 of FIG. 3) ofsheets 21a. The studs 27a are then inserted through the holes in thecase, sheets and strip 29a and heads 33a formed as before. End leaves23a may be glued or otherwise attached by use of adhesive to the insideof covers 56a before or after strips 26a, 29a are installed, or thisstep may be eliminated entirely.

FIG. 17 and FIG. 18 illustrate a further modified book. Many of themodifications are similar to the preceding, and the same referencenumerals, followed by the subscript b, are used to designate similarelements. In this modification a covering 47b is initially placed understrip 26b and is apertured to receive the studs of said strip. Afterstrip 29b has been secured as has been described in the fabrication ofthe uncased book of FIGS. 5-8, then covering 47b is drawn over theoutside of strip 26b, around the spine of the book and then around theoutside of strip 29b. A tool 71 is used to trim the covering 47b toproper size and to tuck the edge thereof under the inner edge of strip29b. If desired, the inner surface of covering 47b may bepressure-sensitive or the covering may be caused to remain in place byadhesive or various other means.

What is claimed is:

1. A cased book comprising an uncased book having a plurality of sheets,front and back end leaves on the outside of said uncased book, each saidend leaf having pressure-sensitive material on its outer surface, andbinding means binding said end leaves and sheets together so that saidend leaves are securely bound to said sheets prior to assembly of saiduncased book to a case; and a case for said uncased book having frontand back covers, a flexible spine and covering means for the outsides ofboth said front and back covers and of said spine, said case prior toadherence to said uncased book being adapted to encase a range ofthicknesses of uncased books by reason of the flexibility of said spine,said end leaves permanently adhering to the insides of said front andback covers by means of said pressuresensitive material, saidpressure-sensitive material extending to the outer edges of said endleaves, the outer edges of said covers extending outwardly beyond theouter edges of said end leaves, said indices of said covers being devoidof exposed adhesive beyond the outer edges of said end leaves, the spineedge of said uncased book being centered relative to said flexiblespine.

2. A book according to claim 1 which further comprises a spine strip ofresilient material extending longitudinally down the middle of saidflexible spine and a resilient pad having pressure-sensitive materialcentered relative to said spine to the spine edges of said uncased book.

3. A cased book comprising an uncased book formed of sheets each formedwith a plurality of first apertures along the inner margins of saidsheets, at least one front and back end leaf on the outside of saidsheets each formed with a plurality of second apertures corresponding tothe spacing of said first apertures, a first narrow plastic strip formedwith a plurality of third apertures corresponding to the spacing of saidfirst apertures and overlying one edge of one of said end leavesadjacent to the inner edge of the side of said uncased book oppositesaid first plastic strip, means on the ends of said studs securing saidstuds to said first strip to form an uncased book, said end leaves eachbeing provided with pressure-sensitive adhesive on its outer surface andinitially protected by a removable protective cover, each said end leafbeing securely bound between said plastic strips to said sheets; and acase for said uncased book having front and back covers and a flexiblespine, and covering means for the outsides of both said front and backcovers and of said spine, said case prior to adherence to said uncasedbook being adapted to encase a range of thicknesses of uncased books byreason of the flexibility of said spine, said end leaves permanentlyadhering to the insides of said front and back covers by means of saidpressuresensitive adhesive after said protective covers have beenremoved, said pressure-sensitive material extending to the outer edgesof said end leaves, the outer edges of said covers extending outwardlybeyond the outer edges of said end leaves, said insides of said coversbeing devoid of exposed adhesive beyond the outer edges of said endleaves, the spine edge of said uncased book being centered relative tosaid spine portion of said covering.

4. A book according to claim 3 which further comprises a spine strip ofresilient material extending longitudinally down the middle of saidflexible spine and pressure-sensitive material on said spine stripadhering said spine strip to the spine edge of said uncased book.

5. A book according to claim 3 in which said spine strip extends overthe outsides of both said plastic strips.

6. A book according to claim 5 in which said covering means is formedwith creases between the outside edge of each said strip and the insideedge of the adjacent cover.

7. A book according to claim 6 in which covering means and said plasticstrips form beads along each spine edge of said cased book.

UNITED STATES PATENT OFFICE CERTIFICATELOEQQCLO R'RE CQTION Patent no.3,730,560 Dated ma 1, 1973 Inventor(s) H y AL.

It is certified thaterror appears in the above-identified patent andthat said Letters Patent are hereby corrected asshown below:

Column 6,- cancel Claim 3 and substitute the following:

3. A cased book comprisingjan uncased book formed of sheets each formedwith a plurality of first apertures along the inner margins of saidsheets, at least one frontand back end leaf on the outside of saidsheets each formed with a plurality of second apertures corresponding tothe spacing of said first apertures,

a first narrow plastic strip fomedwith a plurality of third aperturescorresponding to the spacing of saidfirst apertures and overlying oneedge of one of said end leaves adjacent to the inner edge of the side ofsaid uncased book, a second narrow'plastic strip formed with a pluralityof studs corresponding in sapcing to and projecting. through said first,second and third apertures and overlying the edge of the other of saidend leaves adjacent to the inner edge of the side of said uncased bookopposite said first plastic strip, means" on treends of said studssecuring said studs to said first strip to form an uncased book, saidend leaves each being provided with pressure-sensitive adhesive on itsouter surface" and initially protected by a removable protective cover,each said end leaf being securely bound' betw'een'said plastic strips tosaid sheets, and a case for said uncased book having front, and

FORM PO-IOSO (10-59) USCOMM' DC Gov-6* U.S. GOVERNME NT PRINTING OFFICE:I909 0-366-334.

PATENT NO. 3,730,550

s PAGEHZ. i. .7

back covers and a flexible spine, and covering means for the outsides ofboth said front and back covers and of said spine, said case prior toadherence tov said uncased book being adapted to encase a range ofthicknesses of uncased books by reason of the fletibility of said spine,said end leaves permanently adhering to the insides of said front andback covers by means of said presuresensitive adhesive after saidprotective covers have been removed, said pressuresensitive materialextending to the outer edges of said end leaves, the outer edges of saidcovers extending outwardly beyond the outer edges of said end leaves,said insides of said covers being devoid of exposed adhesive beyond theouter ledges of said end leaves, the spine edge of said uncased bookbeing centered relative to said spine portion of said covering.

Signed and sealed this 25th day of December 1973.

(SEAL) Attest:

EDWARDIM; FLElCHER,JR RENE D. "IEGTMEYER t At testing Officer ActingCommissioner of Patents

1. A cased book comprising an uncased book having a plurality of sheets,front and back end leaves on the outside of said uncased book, each saidend leaf having pressure-sensitive material on its outer surface, andbinding means binding said end leaves and sheets together so that saidend leaves are securely bound to said sheets prior to assembly of saiduncased book to a case; and a case for said uncased book having frontand back covers, a flexible spine and covering means for the outsides ofboth said front and back covers and of said spine, said case prior toadherence to said uncased book being adapted to encase a range ofthicknesses of uncased books by reason of the flexibility of said spine,said end leaves permanently adhering to the insides of said front andback covers by means of said pressure-sensitive material, saidpressure-sensitive material extending to the outer edges of said endleaves, the outer edges of said covers extending outwardly beyond theouter edges of said end leaves, said indices of said covers being devoidof exposed adhesive beyond the outer edges of said end leaves, the spineedge of said uncased book being centered relative to said flexiblespine.
 2. A book according to claim 1 which further comprises a spinestrip of resilient material extending longitudinally down the middle ofsaid flexible spine and a resilient pad having pressure-sensitivematerial centered relative to said spine to the spine edges of saiduncased book.
 3. A cased book comprising an uncased book formed ofsheets each formed with a plurality of first apertures along the innermargins of said sheets, at least one front and back end leaf on theoutside of said sheets each formed with a plurality of second aperturescorresponding to the spacing of said first apertures, a first narrowplastic strip formed with a plurality of third apertures correspondingto the spacing of said first apertures and overlying one edge of one ofSaid end leaves adjacent to the inner edge of the side of said uncasedbook opposite said first plastic strip, means on the ends of said studssecuring said studs to said first strip to form an uncased book, saidend leaves each being provided with pressure-sensitive adhesive on itsouter surface and initially protected by a removable protective cover,each said end leaf being securely bound between said plastic strips tosaid sheets; and a case for said uncased book having front and backcovers and a flexible spine, and covering means for the outsides of bothsaid front and back covers and of said spine, said case prior toadherence to said uncased book being adapted to encase a range ofthicknesses of uncased books by reason of the flexibility of said spine,said end leaves permanently adhering to the insides of said front andback covers by means of said pressure-sensitive adhesive after saidprotective covers have been removed, said pressure-sensitive materialextending to the outer edges of said end leaves, the outer edges of saidcovers extending outwardly beyond the outer edges of said end leaves,said insides of said covers being devoid of exposed adhesive beyond theouter edges of said end leaves, the spine edge of said uncased bookbeing centered relative to said spine portion of said covering.
 4. Abook according to claim 3 which further comprises a spine strip ofresilient material extending longitudinally down the middle of saidflexible spine and pressure-sensitive material on said spine stripadhering said spine strip to the spine edge of said uncased book.
 5. Abook according to claim 3 in which said spine strip extends over theoutsides of both said plastic strips.
 6. A book according to claim 5 inwhich said covering means is formed with creases between the outsideedge of each said strip and the inside edge of the adjacent cover.
 7. Abook according to claim 6 in which covering means and said plasticstrips form beads along each spine edge of said cased book.